Forklift Safety Written Program

University of California Santa Barbara

FORKLIFT SAFETY WRITTEN PROGRAM

Lead: John M. Seaman

Campus General Safety Supervisor

Phone: (805)893-5288
E-Mail: jseaman@ucsb.edu
Team: EH&S/General Safety

Description: This program guides all aspects of the Forklift/Powered Lift Truck Safety
Program for the University of California Santa Barbara (UCSB). As mandated by Cal/OSHA and
other regulatory compliance codes, this program guides compliance with, and application of, all
legal requirements for UC Santa Barbara departments, field stations and work/research
operations that own, rent or use this type of equipment

EH&S RESPONSIBILITIES
EH&S /General Safety Staff, under the direction of the Campus General Safety
Supervisor will:

1. Develop a forklift/powered lift truck safety written program and revise it as necessary
2. Ensure that training is provided to all forklift operators as requested by their campus
department
3. Maintain training records and issue certificate of training to authorized operators whom
have successfully completed all phases of the required operator training
4. Provide technical support to departments and/or staff when questions arise regarding
forklift safety issues, regulations, or purchase requests for forklifts
5. Maintain a tracking system for all for all forklift equipment and authorized operators

Training:

EH&S/General Safety staff has developed a forklift operator safety certification program and can
provide forklift operator safety training for departments, field stations and work/research
operations that use these types of equipment. This program guides all aspects of the campus.
Training includes a combination of formal classroom instruction, demonstrations, “hands-on”
practical exercises, written examination, and an operator skills performance evaluation. Practical
exercises are performed under the supervision of experienced trainers in a controlled
environment to preclude endangering the trainee or other employees. A certificate of training
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University of California Santa Barbara

and operator license will be issued upon completion of the course. To arrange for training, or
obtain further information, contact the EH&S/General Safety staff at 805.893.5407.
Note: No individual is permitted to operate a university-owned lift prior to successfully
completing this certification training program, regardless of previous experience or
certification. Trainees/operators must be at least 18 years of age and hold a valid driver’s
license.

PROCUREMENT SERVICES RESPONSIBILITIES

Prior to the purchase or rental of any forklift or motorized pallet jack, the proposed
purchase order must be reviewed and approved by EH&S/General Safety Staff. This is to insure
that the equipment is suitable for the type of work being performed, the atmosphere in which the
equipment will be operated, and that the following minimum safety equipment is present:
1. Data Plate – reflecting attachments or options that have a direct effect on the lifting capacity
of the equipment
2. Overhead Guard
3. Load backrest
4. Seatbelt- for sit down operated forklifts
5. Horn
6. Headlights
7. Audible back-up indicator
8. Strobe light - to indicate engine is running
9. Headlights
10. Emergency Brake
11. Speed Control – “Rabbit/Turtle” for motorized pallet jacks

OWNER/USER DEPARTMENT RESPONSIBILITIES

Departments that own, lease, rent and/or otherwise operate forklifts and other types of
industrial lift trucks must:

1. Select and then purchase or rent appropriate equipment for job tasks based upon the work-
environment and the completion of a job/task hazard analysis.
2. Ensure personnel are properly trained, licensed and authorized to operate the specific
type(s) of owned/rented equipment, in accordance with established campus guidelines.
The department must post a list of trained and authorized operators in a conspicuous
location.
3. Conduct documented safety inspections and preventive maintenance of the equipment.
4. Purchase and supply all required personal protective equipment (PPE) for persons trained
and authorized to operate forklifts and industrial lift trucks.
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University of California Santa Barbara

5. Assure operators adhere to specific safe-work practices whenever using these types of
powered industrial equipment including use of personal protective equipment (PPE) as
required.
6. Approve Contractors/Vendors to use forklift/industrial lift truck equipment on their
premises, and only allow properly licensed contractor/vendor personnel to use
Department-owned equipment.

Note: Contractors/vendors must have proof of training and licensing to operate

this equipment equal to or exceeding the established requirements for UCSB
personnel.

DEPARTMENT MANAGERS/PIs/SUPERVISORS:
1. Ensure that the forklift being purchased includes the options listed in the Procurement
Services section of this program.
2. Contact EH&S/General Safety so that tracking information can be updated.
3. Ensure that the operating manual has been received, made available to each forklift
operator, and the operating manual is stored within the department for future reference.
4. Acquire the parts and service manuals within 60 days of the acquisition of a forklift.
5. If buying used, have an annual inspection performed prior to placing the forklift in service.
6. Arrange for the manufacturer or approved vendor to provide initial “Forklift
Familiarization Training” to the department’s operators. Provide EH&S/General Safety
with documentation of Forklift Familiarization Training.
7. Ensure that all employee operators of the forklift have reviewed the forklift operator’s
manual.
8. Ensure the inspection and repair of the forklift:
a. The department shall ensure that pre-start inspections and annual inspections are
being performed on the forklift.
b. The department who owns the forklift shall use a pre-start inspection form based upon
the manufacturer’s recommendations found in the operating manual that is consistent
with the one found in Appendix A, including a location where the operator initials and
dates it.
c. When safety related concerns have been discovered the forklift shall be taken out of
service and tagged “DO NOT OPERATE” until the item(s) has been repaired.

9. Ensure that all forklift operators and users are trained and observe safe practices:
a. The department is responsible for arranging for the safety training of all new
authorized forklift operators by contacting EH&S/General Safety.
b. Ensure that operators receive “forklift familiarization training” from competent
operator/trainers (provided/authorized by EH&S/General Safety) Departments must
document this training
c. When renting a forklift, departments shall require that the rental agency provide a
demonstration of forklift operation upon delivery of the rental equipment.
d. Ensure that no personnel operate a forklift if they have not been trained in both, the
classroom forklift training and the forklift familiarization training for that classification
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University of California Santa Barbara

of forklift. The operators must have a certification that authorizes them to operate the
classification of forklift.
e. Ensure that no personnel be elevated by, ride upon, or be transported upon a
forklift under any circumstances. Doing so will result in automatic suspension
of the operator’s license, certification, and authorization to operate forklifts on
behalf of the University of California Santa Barbara.
f. Provide flexibility for forklift operators by giving them the discretion of stopping the job
if, at any time, they have concerns for their safety. It shall be the operator’s discretion
to terminate their work activities while using a forklift.
g. If selling, donating, or destroying forklifts:
1. Prior to the donation, sale, or destruction of a forklift, the department owning
said equipment shall contact EH&S/General Safety to ensure that appropriate
steps are taken.
10. Each department shall date, sign, and retain the following records for each forklift they
own:
a. Serial number and date of purchase (this shall be kept for as long as the
department owns the forklift).
b. Written records of the annual inspections and repairs performed. This shall include
deficiencies found, corrective actions taken and the identification of the person(s)
who performed the inspection and repairs.
c. All pre-start inspections that have been performed for each forklift used.
d. Training records for employees who have received the forklift familiarization
training for each classification of forklift that they use.

OPERATOR RESPONSIBILITIES
Because the forklift operator has direct control over the application and operation of a forklift,
conformance to established campus safety practices is the responsibility of the forklift operator.
Decisions on the use and operation of forklifts shall be made with the understanding that the
safety of the operator and others nearby is dependent on using sound judgement. Forklift
operators have responsibilities including the following:

1. Through the classroom forklift safety training and the forklift familiarization training, the
operator is expected to know and understand the following about the forklifts they operate,
prior to their initial use:

a. The safe operation of the forklift.

b. Hazardous conditions which jeopardizes safety.

c. All control features of the forklift.

d. All placard warnings.

e. All safety devices on the forklift.

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University of California Santa Barbara

f. Where to locate the operator’s manual.

g. Who is authorized/permitted to operate the forklift.

2. If the operator does not understand any of the above they shall consult with their
supervisor prior to using the forklift to ensure a full understanding.

3. Perform Pre-Start Inspections:

a. Users shall inspect the forklift as required by their department and this program to ensure
proper operation.
b. All users shall perform pre-start inspections on the forklift prior to each day’s (or shift’s)
use of the forklift. Documentation of the pre-start inspections shall be performed by
completing a “Forklift Pre-Start Inspection Form”
c. Forklifts that are not in proper operating condition shall be immediately removed from
service and reported to the appropriate supervisor.
d. Operators shall notify their supervisor if the forklift does not safely pass inspection or if
any unsafe condition is identified.

4. If, at any time, the operator is concerned for their safety, they may, at their discretion,
park the forklift in accordance with established best practices and remove the keys.

5. Only trained and authorized employees may operate or use a forklift.

FORKLIFT OPERATOR SAFETY TRAINING

All operators and users of forklifts shall attend a forklift safety training class sponsored
by EH&S/General Safety staff prior to using or operating a forklift. Previous experience
or licensing before becoming a University of California Santa Barbara employee does
not qualify you to operate a forklift.

Contents of the classroom portion of operator training will include the following:

 Purpose and use of manuals and where they must be located

 Authorization to operate.

 Pre-use inspection process.

 Identification of malfunctions and problems.

 Data plate information

 Factors affecting stability.

 Comparison of a forklift to an automobile.

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University of California Santa Barbara

 Purpose of placards and decals.

 Safety rules and regulations.

 Precautions for refueling / recharging

 Operator warnings and instructions

 Loading Dock and Ramp precautions

 Required Personal Protective Equipment (PPE)

Forklift Category Familiarization Training & Operator Skills Evaluation:

All forklift operators shall attend “Forklift Category Familiarization Training” session that is
specific to the category of forklift that they will be operating. The training shall be provided by
EH&S/General Safety staff.

Upon successful completion of the classroom training, familiarization training and forklift operator
skills/performance evaluation a certification card, and certificate of completion will be issued.
Copies will be provided to the employee and the department.

Trained/certified operators must be authorized to operate forklift equipment by their department

prior to operation of said equipment. Authorization must be in writing.

Re-training (both classroom and forklift familiarization sessions):

Will be required of any operator that has been involved in a forklift incident, has been observed
exhibiting any unsafe practices involving a forklift, or has been involved in a “near miss” incident.

INSPECTIONS & MAINTENANCE

The inspection process is a critical step in preventing forklift incidents that are caused from faulty
or worn out equipment. Forklifts that are not in proper operating condition shall be removed from
service until the problems have been corrected by an authorized and trained maintenance
technician.

Pre-Use Inspections
Before each day’s use, or at the beginning of each shift that the forklift is used (whichever comes
first), it shall be given a pre-use inspection. This involves both visual inspection and functional
tests that includes the following criteria:

 Operating and emergency controls.

 Safety devices such as horn, seatbelt, brake lights, audible back-up alarm, and
flashing/rotating beacons.

 Brake systems and steering systems.

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University of California Santa Barbara

 Hydraulic and fuel system leaks.

 Cables and wiring harness.

 Loose or missing parts.

 Tires and wheels.

 Placards, warnings, control markings and operating manual(s).

 Overhead guards and load backrests

Removing a Forklift from Service:

Conditions such as hydraulic leaks, poor braking or steering, safety devices not functioning shall
result in immediate removal of a forklift from service.
 Park the forklift in a location that does not block exits, emergency equipment, or prevent
others from performing work. Shift the forklift to neutral, lower the forks, set the parking
brake, turn off the ignition.
 Remove the key from the ignition, notify your supervisor and give them the key.
 Hang a “Do Not Operate” tag from the steering wheel and make a note on the forklift’s
pre-start inspection sheet.

 The forklift is to remain out of service until the problems have been repaired by an
authorized and trained maintenance technician.
 Upon receiving a forklift back after repairs, the forklift operator must immediately perform
another pre-start inspection to verify that everything is functioning properly.

Maintenance
All maintenance that is performed on forklifts shall be performed by trained and experienced
professionals. The owning or renting department shall make arrangements with an approved
vendor/contractor to provide this service.

Forklifts that are being used at a frequency of more than 200 hours of runtime per year shall
have a frequent inspection performed 2 times per year. Forklifts which average fewer than 200
hours of runtime per year will have a frequent inspection that occurs 1 time per year.
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University of California Santa Barbara

These inspections shall be performed by a qualified mechanic who is authorized to perform

maintenance duties and repairs on the forklift. An approved vendor shall be contracted through
the department who owns the forklift. The contractor’s inspection shall include all items specified
by the manufacturer for a frequent inspection. Owner department will:
 maintain copies of all inspections and repairs and,
 provide them upon request to EH&S/General Safety staff for inspection

Battery Charging and Fueling Forklifts:

Shall be done in an environment with adequate ventilation that is free from sparks or open
flames. Where battery charging takes place, an ABC fire extinguisher shall be available within
20 feet of the charging station and these areas are to be designated “No Smoking”. Locations
such as a garage or exterior storage space are approved for propane cylinder storage. While
changing propane cylinders, forklift operators shall wear leather gloves to protect from frostbite
in the event of a propane leak.

Forklift Equipment Alterations/Attachments

The forklift manufacturer must provide written approval for any attachments beyond what was
available upon initial purchase of the equipment. Additional attachments are to be reflected in
the forklift data plate with adjusted forklift capacity calculations.

FORKLIFT OPERATION BEST PRACTICES

Pre-Use Best Practices

 Obtain authorization to use or operate the forklift (certification card and written
department approval).

 Always check the last pre-start inspection for any comments or notes and perform a new
pre-start inspection on the forklift. Document the inspection, and place it in the reserved
storage location on the forklift.

 Be familiar with the equipment owner’s manual and the rated capacity of the equipment.
 When mounting a forklift always maintain three points of contact

 All sit down operated forklifts are to be equipped with a seat belt. Seat belts must be
worn by operators if they are available on the equipment.
Operational Best Practices

 Always keep your head, hands, and feet within the confines of the overhead guard
 Only handle loads that are within the forklift’s rated capacity

 Never allow a person to stand under elevated forklift forks.

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University of California Santa Barbara

 While traveling, yield the right of way to pedestrians and ensure to use your horn at
intersections and when changing directions

 Use extreme caution on grades, ramps, or inclines. Operators should travel straight up
and down, keeping the load upslope.
 Distractions such as eating, drinking, smoking, talking on cell phone, texting are all
prohibited while a forklift is in gear. Stop, shift to neutral, and set the parking brake prior
to a answering/using cell phones or other devices.

 Do not exceed a speed of 5 Miles Per Hour when operating a forklift

 Always look in the direction of travel. This includes when traveling in reverse. If you must
go forward to set down a load and your view is obstructed, use a second person as a
spotter to ensure traffic is clear and to communicate to the driver how much clearance
between the load and any obstructions.

 Always maintain a distance of three lift truck lengths between the forklift being operated
and any other forklifts, elevated work platforms or other types of motorized equipment

 Never carry passengers nor elevate persons standing on either the forks or a pallet.
 Stunt driving or horseplay involving forklifts may result in disciplinary action and/or
revocation of operator status and privileges
 When parking never block doors, emergency exits, or electrical panels

 Prior to dismounting from a forklift: (1) set the parking brake, (2) lower the forks to the
ground, (3) neutralize the controls, (4) turn off the engine, and (5) remove keys from the
ignition if you will be more than 25 feet away from the forklift

Loading Dock Best Practices

 Be aware of loading dock drop offs and ramps to ensure that forklifts do not
unexpectedly tip over the edge.

 Continue to maintain the loading dock areas during rainy or inclement weather
conditions to reduce the risk of a forklift sliding off the loading dock area.

 Forklift operators have the responsibility of ensuring that truck drivers are putting their
truck in park, setting the brakes, and placing a chock under the rear tires.

 Prior to driving into a trailer, check the overhead clearance as well as the condition of
the dock plate and trailer floor to ensure that they will handle the weight of the forklift
and the load you will be transporting.

 Functioning headlights are required when operating a forklift indoors, at night or

working inside a dark trailer.
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University of California Santa Barbara

 Immediately report any forklift related incidents to your supervisor. Supervisors shall
inform EH&S/General Safety staff so that an incident investigation will occur, equipment
inspection may occur, and ensure that the forklift operator is retrained.

IN THE EVENT OF A TIPOVER

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University of California Santa Barbara

APPENDIX A

PRE-USE INSPECTION FORMS

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University of California Santa Barbara

UCSB FORKLIFT OPERATOR SAFETY

DAILY PREVENTIVE MAINTENANCE & INSPECTION REPORT
FOR GAS/DIESEL/LPG POWERED ENGINES

Forklift ID#: ___________ Make: ______________ Model: _______________

Date: ___________ Time: ____________ Hour Meter Reading: _______________

Certified Forklift Operator: Complete this form, before each use. Check “OK” if the items are in good condition/operation or
check the “Repair Required” box if the item is not in proper working order. IMPORTANT: The forklift must not be utilized if
there are any items that require repairs. Report all “Repair Required” items to your supervisor immediately.
Required Operator Inspection Items/Functions
Inspection Item (Visual Check) OK Repair Required Comments/Action Taken
FORKLIFT BODY (Dents)
DATA PLATE & SAFETY DECALS
(Present & Legible)
FUEL LEVEL
OIL LEVEL & OIL PRESSURE
WATER LEVEL
FAN BELT (Serviceable)
ENGINE HOSES (No Leaks/Cuts)
BATTERY (Clean & Serviceable)
TIRES/WHEELS
(Air Pressure/Wear/Bolts Tightened)
HYDRAULIC HOSES
(No Leaks/Cuts/Excessive Wear)
CHAINS
(Not Loose, broken, or worn )
Properly lubricated
MAST (Serviceable)
No worn, broken, or misaligned parts)
FORKS (No Cracks at Joints) Properly
Mounted & Secured
PARKING BRAKE
(Operational : Forward & Reverse)
SERVICE BRAKES (Operational)
Not loose/spongy
STEERING (No Excessive Play)
HYDRAULIC CONTROLS
(Smooth & Continuous Operation)
HORN (Operational)
BACK-UP ALARM (Functioning)
OVERHEAD CAGE
Properly Mounted, No visible damage
WARNING LIGHT (Functional)

INSPECTOR’S NAME (Print): ________________________________________________________

(Signature): ____________________________________________
Note to Supervisors: It is your responsibility to ensure your operators are continually performing and
documenting their pre-use inspections
Forklift Safety Written Program
University of California Santa Barbara

UCSB FORKLIFT OPERATOR SAFETY

DAILY PREVENTIVE MAINTENANCE & INSPECTION REPORT
FOR BATTERY POWERED ENGINES

Forklift ID#: ____________ Make: _____________________ Model: ______________________

Date: __________________ Time: _______________ Hour Meter Reading: _____________________

Certified Forklift Operator: Complete this form, before each use. Check “OK” if the items are in good
condition/operation or check the “Repair Required” box if the item is not in proper working order. IMPORTANT:
The forklift must not be utilized if there are any items that require repairs. Report all “Repair Required” items to
your supervisor immediately!

Required Operator Inspection Items/Functions

INSPECTION ITEM OK Repair Required COMMENTS
FORKLIFT BODY (Dents)
DATA PLATE & SAFETY DECALS
(Present & Legible)
BATTERY CHARGE LEVEL
BATTERY LOAD TEST
BATTERY PLUG CONNECTION
BATTERY (Clean & Serviceable)
TIRES/WHEELS
(Air Pressure/Wear/Bolts Tightened)
HYDRAULIC HOSES
(No Leaks/Cuts/Excessive Wear)
CHAINS
(Not Loose, broken, or worn )
Properly lubricated
MAST (Serviceable)
No worn, broken, or misaligned parts)
FORKS (No Cracks at Joints) Properly
Mounted & Secured
PARKING BRAKE
(Operational : Forward & Reverse)
SERVICE BRAKES (Operational)
Not loose/spongy
STEERING (No Excessive Play)
HYDRAULIC CONTROLS
(Smooth & Continuous Operation)
HORN (Operational)
BACK-UP ALARM (Functioning)
OVERHEAD CAGE
Properly Mounted, No visible damage
WARNING LIGHT (Functional)

INSPECTOR’S NAME (Print): ________________________________________________________

(Signature): _____________________________________________________
Note to Supervisors: It is your responsibility to ensure your operators are continually performing and
documenting their pre-use inspections
Forklift Safety Written Program
University of California Santa Barbara

UCSB FORKLIFT OPERATOR SAFETY

DAILY PREVENTIVE MAINTENANCE & INSPECTION REPORT
FOR MOTORIZED/ BATTERY POWERED PALLET JACKS

Forklift ID#: ____________ Make: _____________________ Model: ______________________

Date: __________________ Time: _______________ Hour Meter Reading: _____________________

Certified Motorized Pallet Jack Operator: Complete this form, before each use. Check “OK” if the items are in
good condition/operation or check the “Repair Required” box if the item is not in proper working order.
IMPORTANT: The forklift must not be utilized if there are any items that require repairs. Report all “Repair
Required” items to your supervisor immediately!

Required Operator Inspection Items/Functions

INSPECTION ITEM OK Repair Required COMMENTS
PALLET JACK BODY (Dents)
BATTERY CHARGE LEVEL
BATTERY LOAD TEST
BATTERY PLUG & CONNECTOR
BATTERY (Clean & Serviceable)
TIRES/ LOAD WHEELS
(Serviceability/Wear/Bolts Tightened)
HYDRAULIC HOSES
(No Leaks/Cuts/Excessive Wear)
DATA PLATE AND SAFETY DECALS
(Present, Legible )
FORKS (No Cracks at Joints)
KEY SWITCH (Functional)
SPEED CONTROLS (Rabbit/Turtle)
(Operational)
SERVICE BRAKES (Operational)
Not loose/spongy
STEERING (No Excessive Play)
HYDRAULIC CONTROLS
(Smooth & Continuous Operation)
HORN (Operational)
FORWARD/REVERSE CONTROLS
(Functioning)
WARNING LIGHT (Functional)

INSPECTOR’S NAME (Print): ________________________________________________________

(Signature): _____________________________________________________

Note to Supervisors: It is your responsibility to ensure your operators are continually performing and
documenting their pre-use inspections
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University of California Santa Barbara

ANNEX B

FORKLIFT CLASSIFICATIONS CHART

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University of California Santa Barbara

LIFT TRUCK CLASSIFICATIONS CHART

CLASS I.
ELECTRIC MOTOR COUNTER-
BALANCED RIDER TRUCKS
These forklifts can be equipped with either
cushion or pneumatic tires. The cushioned
tires are designed for indoor use on smoot,
dry floors. They are very versatile and are
typically used where air quality factors need
to be considered

CLASS II.
These are designed for use in narrow
aisles in warehouses allowing for maximum
available storage space. They minimize the
ELECTRIC MOTOR space occupied by the lift truck and improve
NARROW AISLE TRUCKS speed and efficiency

CLASS III.
These are battery powered, hand-controlled
lift trucks. They are lower capacity rated than
ELECTRIC MOTOR sit-down lift trucks. All controls are mounted
HAND TRUCKS on the tiller with the tiller moved side to side
to steer the truck

CLASS IV.
Designed for use indoors on smooth dry
floors. Most often used on loading docks
INTERNAL COMBUSTION plants & warehouses where power,&
COUNTER BALANCED TRUCKS continuous usage are expected, and good
(Cushion Tires) maneuverability is important

CLASS V.
These trucks are most commonly used in
warehouses, lumberyards, wineries, and
INTERNAL COMBUSTION production facilities. These lift trucks can be
COUNTERBALANCED powered by LPG, Gasoline, or Diesel fuel.
TRUCK (Pneumatic Tires)

CLASS VI.
These versatile trucks can be used in a
variety of applications such as commercial
ELECTRIC & INTERNAL aviation, and facility maintenance. They are
COMBUSTION TOW TRACTORS designed for either indoor or outdoor usage

CLASS VII.
Rough Terrain forklifts are fitted with large
floatation tires for outdoor use on difficult
ROUGH TERRAIN surfaces. They are most commonly used on
FORKLIFT TRUCKS construction sites to transfer and lift building
materials to various job site locations. They
are also commonly used in lumber yards and
auto recycling facilities